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TRANSFER CASE
2D-37
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(4) Install 0.060-0.063 Inch (1.52-1.60 mm) inner
snap ring if removed.
(5) Install bearing so shielded side faces interior of
bore and tap bearing inward until seated against inner
snap ring.
(6) Determine required snap ring thickness using
Gauge Tool J-25163. Install thickest snap ring possible
that will provide 0.001 to 0.003 inch (0.02 to 0.07 mm)
bearing end play.
Control Diaphragm-Shift Fork-Logfcup Hub
Removal
(1) Remove vent cover and seal ring.
(2) Remove retaining rings which position shift fork
on diaphragm rod.
N O T E : The shift fork may be pried slightly forward or
rearward to gain access to the retaining rings.
(3) Remove poppet spring from spring bore using
magnet.
N O T E : The diaphragm control rod is held in position
by a poppet ball and spring (fig. 2D-43).
(4) Insert magnet into poppet spring bore and re-
move control diaphragm (fig. 2D-59).
(5)
1
Remove poppet ball using magnet.
(6) Remove shift fork and shifting shoes.
(7) Remove lockup hub.
Installation
(1) Lubricate shifting shoes with Quadra-Trac lub-
ricant, or equivalent, and install shoes in shift fork.
(2) Install lockup hub in shift fork (fig. 2D-60).
Fig. 2D-53
Control Diaphragm Removal
L O N G SIDE
T O R E A R
T O F R O N T
J 4 2 4 1 0
Fig. 2D-60
Assembling Shift Fork and Lookup Hub
(3) Install assembled shift fork and lockup hub in
rear cover. Be sure fork is installed so long side of fork
boss faces rearward. Reach through differential needle
bearing and support fork and hub with fingers to pre-
vent assembly from separating during installation.
(4) Insert control diaphragm rod into cover and
through shift fork. Do not insert rod beyond poppet ball
and spring bore in cover.
(5) Install poppet spring and ball in cover bore.
(6) Press spring and ball downward using 1/4-inch
pin punch and slide control diaphragm rod past poppet
ball.
(7) Install shift fork retaining clips.
(8) Install control diaphragm retaining spring.
Spring should seat below edge of hole.
(9) Install vent cover seal ring and vent cover.
Transfer Casi Assembly
(1) Remove old sealant from front and rear cover
mating surfaces using razor blade or gasket scraper
having sharp blade.
(2) Lubricate all bearing and thrust washer sur-
faces with Jeep Quadra-Trac Lubricant or equivalent
only.
(3) Position drive sprocket on wood block (fig. 2D-
45).
(4) Position differential sprocket approximately 2
inches (5.08 cm) from drive sprocket and with front end
of differential resting on bench.
(5) Install chain around drive and differential
sprockets. Be sure chain is properly engaged with
sprocket teeth and that all slack is removed from chain
(fig. 2D-46).
(6) Insert rear output shaft in differential.
(7) Move lockup hub rearward in case cover.
(8) Lubricate drive sprocket thrust washer with
Quadra-Trac lubricant or equivalent only, and install
washer on rear cover (fig. 2D-47).
(9) Align and install rear cover on sprockets. Rotate
output shaft to align with lockup hub if necessary. Be
sure drive sprocket thrust washer is not displaced dur-
ing cover installation.
(10) Assemble drive hub, drive sleeve, and drive
sleeve snap ring (fig. 2D-61).
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Troubleshooting
